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Analysis And Solutions Of Six Common Problems Of Precision Cnc Machining

Views:53     Author:Site Editor     Publish Time: 2021-06-30      Origin:Site

In the process of precision cnc machining, the processed products are often backfired due to some one or other reasons. There are also many newcomers who often encounter many problems and failures. Today, the cnc machining company - Kingka summarized the solutions for several problems such as overcutting of the workpiece, tool setting failure, centering, collision caused by operation, collision caused by programming, and insufficient surface accuracy. Let's learn together. 


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The workpiece is overcut

There are several reasons for this situation:

1. The strength of the tool is not enough, or the tool is too long or the tool is too small, which causes the tool to appear snapped;

2. Irregular operation of the operator;

3. The cutting margin is not even enough;

4. It is caused by improper setting of cutting parameters, for example, the tolerance is too large or the SF setting is too fast;


Ways to improve:

1. When choosing a tool, try to follow the rules that can be big or not, and can be short and not long;

2. Add the corner cleaning program, and keep the margin as even as possible;

3. Reasonable adjustment of cutting parameters, rounding corners with large margins;

4. Using the SF function of the equipment, the operator fine-tunes the speed so that the CNC machine tool can achieve better results;


Tool setting failure

The main reasons for tool setting failure are:

1. Operator error;

2. The clamping of the tool is wrong;

3. The blade on the flying knife is wrong;

4. There is an error between the flat bottom of the R knife and the flying knife;


The main ways to improve are:

1. Careful inspection is required before manual operation, and the tool setting should be at the same point as much as possible;

2. When the tool is clamped, use an air gun to blow it clean or use a rag to wipe it clean;

3. The same blade can be used when the upper blade of the flying knife needs to measure the tool shaft and the light bottom surface;

4. A separate tool setting program can avoid the error between the R knife flat knife and the flying knife;


In the middle

The main reasons for this phenomenon are:

1. The operator's manual operation is not accurate enough, and manual operation makes mistakes;

2. There are burrs around the mold;

3. The sub-center rod is magnetic;

4. The four sides of the mold are not vertical enough;


The main solutions and improvements are:

1. Check repeatedly before manual operation, and try to be at the same point and height as possible;

2. Use oilstone or a file to remove the burrs around the mold, then wipe it clean with a rag, and then confirm it by hand;

3. Demagnetize the centering rod before centering the mold;

4. Verify and check whether the four sides of the mold are vertical;


The collision caused by the operator

The main reasons for this phenomenon are as follows:

1. Depth Z axis tool setting error;

2. The number of hits in the score and the operation error;

3. The wrong knife was used;

4. There is an error in the program;

5. The handwheel is turned in the wrong direction during manual operation;

6. The wrong direction was pressed during manual rapid feed;


The main ways to improve are:

1. Be sure to pay attention to the position of the depth Z-axis tool setting;

2. Check repeatedly after the count and operation are completed;

3. When installing the tool, it is necessary to repeatedly check with the program sheet and the program before installing;

4. The program should go in order one by one;

5. In manual operation, the operator should strengthen the machine tool operation proficiency by himself;

6. When moving quickly manually, you can raise the Z axis to the part before moving.


The collision caused by the procedure

The main reasons are:

1. The safety height is not enough or the safety height is not set at all;

2. The tool on the program sheet is different from the actual program tool;

3. There is an error between the tool length on the program sheet and the actual machining depth;

4. The depth Z-axis access on the program sheet is wrong with the actual Z-axis access;

5. The coordinates are set incorrectly during programming;


The main solutions are:

1. Accurately measure the height of the parts and ensure that the safety height is above the parts;

2. The tool on the program sheet must be consistent with the actual program tool;

3. Measure the actual machining depth on the workpiece, and write clearly the length of the tool and the length of the blade on the program sheet;

4. The actual number of Z-axis access on the part should be clearly written on the program sheet;


The surface accuracy is not accurate

The main reasons for this phenomenon are:

1. The cutting parameters are not reasonable enough, and the surface of the part is rough;

2. The cutting edge of the tool is too blunt;

3. The tool is clamped too long, and the clearance of the blade is too long;

4. Chip removal, air blowing and oil flushing are not good enough;

5. There is a problem with the way of programming the knife;

6. There are burrs on the surface of the part;


The main ways to improve are:

1. The setting of cutting parameters should be reasonable, such as tolerance, margin, speed follow-up feed, etc.;

2. The operator of the tool should inspect from time to time and replace the tool regularly;

3. When clamping the tool, the operator is required to clamp as short as possible, and the blade should not be too long to avoid the air;

4. For the down-cutting of flat knife, R knife, and round nose knife, the speed and feed setting should be reasonable;

5. The appearance of burrs on the surface of parts and components has a lot to do with our equipment, tools and the way of cutting. Therefore, it is necessary to know enough about the performance of the cnc machining center to make up the edges with burrs;


The above is the cause analysis and solutions for several problems such as overcutting of the workpiece, tool setting failure, centering, collision caused by operation, collision caused by programming, and insufficient surface accuracy. I hope it can be helpful to you.


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Tel: +86 (769) 87636775
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Kingka Tech Industrial Limited, founded in 2010, is a professional aluminum alloy processing manufacturer specializing in precision CNC machining. King’s product range is from all kinds of heat sinks to structure parts. Our products are widely applied in telecom, aerospace, automotive, industrial control, power electronics, medical instrument, security electronics, LED lighting and multimedia/consumer etc. 

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